A multi-parameter integrated online monitoring system for hydraulic hoist

Abstract

The utility model belongs to the technical field of hydraulic engineering equipment monitoring, provide a kind of multi-parameter integrated on-line monitoring system for hydraulic hoist, the sensor monitoring module used in the utility model includes mechanical structure monitoring module, is set on the rack and key force component of hydraulic hoist;Power source monitoring module is set in the oil tank and hydraulic pump outlet pipeline of hydraulic system, for collecting hydraulic oil quality and pump operating state data;Valve group monitoring module is set on the control valve group of the hydraulic system of hydraulic hoist, for collecting the working state data of various valve parts;Actuator monitoring module is set in the rod cavity, rodless cavity and cylinder body outer wall of hydraulic cylinder, for collecting the pressure, vibration and displacement data of hydraulic cylinder.The utility model covers the mechanical structure, power source, control valve group and actuator required for the operation of hydraulic hoist, can comprehensively reflect the overall health condition of hydraulic hoist, provides sufficient data support for fault early warning and diagnosis.

Description

Technical Field

[0001] This utility model belongs to the field of water conservancy engineering equipment monitoring technology, specifically, it relates to a multi-parameter integrated online monitoring system for hydraulic gate hoists. Background Technology

[0002] As the core driving device for gates in water conservancy projects, the hydraulic gate hoist's operating status directly affects the safety and stability of the entire gate system. A typical hydraulic gate hoist system includes a hydraulic pump station that provides power to the entire system, hydraulic cylinders as actuators, control valve groups that control the direction and pressure of the oil circuit, and auxiliary components such as oil tanks and oil pipes.

[0003] Currently, monitoring the operational status of hydraulic gate hoists has become a crucial aspect of gate system monitoring. Several targeted monitoring solutions exist in the existing technology. For example, utility model patent CN223107223U discloses a real-time online monitoring system for a ship lock's reverse-arc gate, which monitors the mechanical condition of the hydraulic gate hoist frame by setting up a working stress monitoring unit and a vibration acceleration monitoring unit. Another example is invention patent CN116242431A, whose technical solution also focuses on evaluating the hoist's status through a vibration monitoring module and a frame stress monitoring module.

[0004] However, the aforementioned existing technologies mainly focus on vibration and stress monitoring of mechanical structures, with relatively limited monitoring parameter types. Furthermore, as a complex hydraulic-electric integrated system, the failures of hydraulic gate hoists are not only manifested in the mechanical structure but also frequently occur within the hydraulic system itself (such as abnormal pressure, oil contamination, and overheating). Existing solutions lack simultaneous monitoring of core hydraulic system operating parameters (such as pressure, flow rate, oil temperature, and cleanliness), resulting in incomplete monitoring dimensions. This makes it difficult to comprehensively and scientifically reflect the overall health status of the hydraulic gate hoist and fails to provide sufficient data support for fault early warning and diagnosis. Utility Model Content

[0005] The purpose of this invention is to provide a multi-parameter integrated online monitoring system for hydraulic gate hoists, so as to solve the technical problems existing in the prior art.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A multi-parameter integrated online monitoring system for hydraulic gate hoists includes a sensor monitoring module for data acquisition, a data acquisition unit for acquiring sensor data, and an edge computer communicating with the data acquisition unit. The sensor monitoring module includes a mechanical structure monitoring module installed on the frame and key force transmission components of the hydraulic gate hoist to acquire operational data of the mechanical structure; a power source monitoring module installed on the oil tank and hydraulic pump outlet pipeline of the hydraulic system to acquire hydraulic oil quality and pump operating status data; a valve group monitoring module installed on the control valve group of the hydraulic system of the hydraulic gate hoist to acquire working status data of various valves, including throttle valves, main valves, pilot valves, solenoid valves, directional valves, electromagnets, and proportional valves; and an actuator monitoring module installed in the rod chamber, rodless chamber, and outer wall of the hydraulic cylinder to acquire pressure, vibration, and displacement data of the hydraulic cylinder.

[0008] Preferably, the power source monitoring module includes: an oil fluid integrated sensor, installed in the oil tank, for collecting data on the contamination level, moisture content, and oil temperature of the hydraulic oil; a vibration sensor, installed on the outlet pipeline of the hydraulic pump, for collecting vibration signals of the hydraulic pump; and a pressure sensor, installed at the outlet of the hydraulic pump, for collecting main pressure data of the hydraulic system.

[0009] Preferably, the valve group monitoring module includes a valve body vibration sensor installed on the valve body of the proportional valve, directional valve, or relief valve; a pilot pressure sensor installed in the pilot control oil circuit where the pilot valve is installed; a set of downstream pressure sensors installed at the inlet and outlet ports of the directional valve or proportional valve; and an electromagnet current sensor integrated in the drive circuit of the solenoid valve or proportional valve for collecting the drive current waveform data of the electromagnet.

[0010] Preferably, the valve group monitoring module further includes a pressure compensator monitoring module, which is a differential pressure sensor. Its two pressure taps are respectively connected to the front and rear ends of the throttle valve port controlled by the pressure compensator, and are used to directly collect the working differential pressure data of the valve port.

[0011] Preferably, the actuator monitoring module includes: a dual-chamber pressure sensor, respectively disposed in the oil ports of the rod chamber and the rodless chamber of the hydraulic cylinder; a cylinder vibration sensor, installed on the outer wall of the hydraulic cylinder; and a draw rope displacement sensor, used to measure the displacement of the hydraulic cylinder piston rod.

[0012] Preferably, the actuator monitoring module further includes a non-contact displacement sensor, which is disposed near the piston rod of the hydraulic cylinder, for redundant verification of the measured values ​​of the displacement sensor in the actuator monitoring module.

[0013] Preferably, the mechanical structure monitoring module includes: a frame vibration sensor, installed on the load-bearing frame of the hydraulic hoist; and a stress sensor, installed on the connecting pin, bearing seat, and lifting head.

[0014] Preferably, the data acquisition device is a multi-channel synchronous acquisition device and communicates with the edge computer via industrial Ethernet or RS-485 bus.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] (1) This utility model integrates a mechanical structure monitoring module, a power source monitoring module, a valve group monitoring module and an actuator monitoring module, covering the mechanical structure, power source, control valve group and actuator required for the operation of the hydraulic gate hoist. Combined with the installation position and selection of sensors, it realizes the synchronous data acquisition and monitoring of multiple parameters of the hydraulic gate hoist. The monitoring dimensions are comprehensive and the sensor settings are scientific and reasonable. It can fully reflect the overall health status of the hydraulic gate hoist and provide sufficient data support for fault early warning and diagnosis analysis.

[0017] (2) This utility model can monitor the early signs of failure such as oil deterioration, component performance degradation, and control valve group failure. Combined with early warning analysis model and AI algorithm model, it can realize early warning and predictive maintenance of potential failures and avoid sudden shutdown accidents.

[0018] (3) The present invention adopts a redundant monitoring design for the displacement monitoring of the hydraulic cylinder piston rod, which ensures the long-term stable operation of the system and the reliability of data in harsh industrial environments.

[0019] (4) The present invention includes a pressure compensator monitoring module, whose monitoring results are used for cross-verification with the valve downstream pressure data, which can effectively ensure the correctness of the data for monitoring pressure compensator faults and avoid misdiagnosis. Attached Figure Description

[0020] Figure 1 This is a schematic diagram illustrating the principle of this utility model. Detailed Implementation

[0021] To enable those skilled in the art to have a clearer understanding of this utility model, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described below are merely illustrative of this utility model and facilitate understanding. The technical solutions provided by this utility model are not limited to those provided in the following embodiments, nor should they limit the scope of protection of this utility model.

[0022] Example

[0023] like Figure 1As shown, this embodiment provides a multi-parameter integrated online monitoring system for hydraulic gate hoists. The system includes a sensor monitoring module for data acquisition, a data acquisition unit for acquiring sensor data, and an edge computer that communicates with the data acquisition unit. Both the data acquisition unit and the edge computer use existing mature equipment. Preferably, the data acquisition unit uses a 16-channel synchronous acquisition device (e.g., TDE-324QI). All analog and digital signals are connected to this acquisition unit to ensure strict synchronization of multi-parameter data, laying the foundation for subsequent correlation analysis.

[0024] The core innovation of this embodiment lies in the construction of the sensor monitoring module, primarily in the deployment of measuring points and sensor selection, ultimately achieving overall health monitoring of the hydraulic gate hoist based on sensor data acquisition. In this embodiment, the sensor monitoring module mainly includes a mechanical structure monitoring module, a power source monitoring module, a valve group monitoring module, and an actuator monitoring module. Detailed descriptions of each module are as follows:

[0025] The mechanical structure monitoring module is mainly used to collect the operating data of the hydraulic hoist mechanical structure and to monitor structural vibration and stress concentration. The sensor measurement point layout and selection based on this monitoring module are as follows: (1) Install frame vibration sensors on the load-bearing frame of the hydraulic hoist. Preferably, select 2-4 industrial ICP type acceleration sensors with a frequency response range of 0.5 Hz to 5 Hz. kHz, respectively fixedly installed at the maximum stress or structurally weak part of the hydraulic hoist frame, such as the middle of the two side columns and the crossbeam; the frame vibration data is used to monitor the overall vibration intensity of the structure, and the prominence of specific high-frequency components in the vibration spectrum can provide early warning of resonance caused by foundation loosening or cavitation and erosion; the trend of vibration energy growth is an early indication of fatigue failure; (2) stress sensors are pasted on the surface of key force transmission components (i.e., connecting pins, bearing seats and hoist heads). Preferably, at least 4 sets of resistance strain gauges are selected and bridged in a full bridge or half bridge manner, respectively tightly attached to the sensitive parts of the surface of connecting pins (2 sets), bearing seats (1 set) and hoist heads (1 set); stress and strain data are used to monitor the dynamic stress of key force transmission components in real time, and the stress amplitude exceeding the material yield limit provides early warning of overload failure; by analyzing the stress spectrum through the rain flow counting method, the fatigue failure life can be predicted.

[0026] The power source monitoring module is mainly used to collect data on hydraulic oil quality and pump operation status. The sensor measurement point layout and selection based on this monitoring module are as follows: (1) Oil comprehensive sensor: Select one embedded online monitoring sensor that integrates laser particle counting, capacitive moisture sensing and PT100 temperature sensing functions (example: integrated Calder OPC-2300; split OPC-1800 desktop liquid particle counter + FP-24C flat embedded capacitive sensor + WZP / P115PT100 probe, and collect data centrally through an embedded gateway (such as Advantech ARK-3532D)). Insert it directly below the oil tank surface; Among them, oil contamination degree and moisture data: are the direct basis for diagnosing hydraulic oil contamination. High particle count is a warning of wear failure risk, and excessive moisture content will accelerate oil aging failure. And cause component corrosion failure; oil temperature data: abnormal oil temperature rise (such as exceeding 65°C) will accelerate oil aging, viscosity decrease leading to poor lubrication, and aggravate wear failure; (2) pump outlet vibration sensor: select a high-frequency response piezoelectric acceleration sensor and install it on a rigid pipeline near the hydraulic pump outlet. By performing spectrum analysis on the vibration signal, the hydraulic pump's cavitation and erosion (characteristic low-frequency envelope), internal bearing or gear wear failure (characteristic high-frequency resonance) and fatigue failure (sideband analysis) can be accurately diagnosed; (3) pump outlet pressure sensor: select a piezoresistive pressure sensor with pulsating pressure measurement capability and install it at the pump outlet. The range is 1.5 times the rated pressure of the system. Excessive pressure pulsation is a typical characteristic of cavitation; slow pressure build-up or failure to reach the set value may indicate severe wear inside the pump or overflow valve failure.

[0027] The valve group monitoring module is mainly used to collect working status data of various valve components. In this embodiment, the control valve group includes throttle valve, main valve, pilot valve, solenoid valve, directional valve, electromagnet and proportional valve. The sensor measurement point arrangement and selection based on the monitoring module are as follows: (1) Valve body vibration sensor: Select several miniature ICP acceleration sensors (at least 2 according to the number of valves) and install them directly on the valve body surface of the proportional valve and relief valve; (2) Pilot pressure sensor: Select 1-2 small high-frequency pressure sensors and connect them to the pilot control oil circuit; (3) Valve downstream pressure sensor group: For key directional valves or proportional valves, install 1 fast-response pressure sensor at each of their inlet and outlet ports, i.e., 2 sensors in a group; (4) Electromagnet current sensor: Select closed-loop Hall current sensor (the number is consistent with the number of monitored electromagnets, at least 1) and non-invasively wrap it on the drive power line of the solenoid valve or proportional valve. The uses of each collected data in fault diagnosis and analysis are as follows: Valve body vibration: When the valve core switches at high frequency, it will generate a specific vibration waveform. Waveform distortion or sudden increase in energy is direct evidence of directional valve failure or proportional valve failure; Pilot pressure: Unstable or insufficient pilot pressure directly leads to main valve failure, manifested as slow or unresponsive main valve core movement; Post-valve pressure: By comparing the pressure difference before and after the valve, throttle valve failure, pressure compensator failure, and internal leakage caused by valve core / valve hole wear can be diagnosed; Electromagnet current: Slow current rise indicates electromagnet aging, persistently high current may be due to short circuit between coil turns, and if the current reaches the target but the valve core does not move, it clearly indicates valve core jamming.

[0028] In the above-mentioned method, the data for diagnosing pressure compensator faults based on downstream pressure is limited and may lead to misdiagnosis. Therefore, in this embodiment, a pressure compensator monitoring module is also provided to directly collect the working differential pressure data of the valve port. This pressure compensator monitoring module is a differential pressure sensor, and its two pressure taps are connected to the two ends of the throttle valve port controlled by the pressure compensator via a three-way connector. For example, if the differential pressure value cannot be kept constant, it indicates that the compensator valve core is stuck or the spring is fatigued and failing. If the differential pressure is not zero under the zero position command, it indicates that there is internal leakage caused by wear of the valve core / valve hole. The monitoring results of the pressure compensator monitoring module need to be cross-verified with the downstream pressure data to ensure the accuracy of the pressure compensator monitoring data.

[0029] The actuator monitoring module is mainly used to collect pressure, vibration and displacement data of hydraulic cylinder. The sensor measurement point layout and selection based on the monitoring module are as follows: (1) Dual-chamber pressure sensor: Two pressure sensors matched with the system pressure are selected and installed in the rod chamber and rodless chamber oil port of the hydraulic cylinder respectively. Abnormal pressure in the two chambers is a direct parameter for diagnosing internal leakage, seal wear failure and load change in the hydraulic cylinder. Severe pressure fluctuation may be related to cavitation phenomenon; (2) Cylinder vibration sensor: One general vibration sensor is selected and installed in the middle of the outer wall of the hydraulic cylinder. Abnormal vibration may be caused by wear of piston support ring, slight bending of piston rod or uneven surface caused by external corrosion failure; (3) Displacement sensor: One high-precision pull rope displacement sensor is selected. Its body is fixed in the cylinder and the pull rope is connected to the piston rod or the suspension point that moves synchronously with the piston rod. The displacement data combined with the pressure data can calculate the system efficiency and diagnose overall aging failure and wear failure.

[0030] The piston rod location data is a crucial core data point. To ensure the reliability of this data, this embodiment also employs a redundant design, namely, a non-contact displacement sensor is installed near the piston rod. One laser displacement sensor is selected as redundancy and aligned with the unpainted measurement point on the piston rod. The redundant configuration of the pull rope sensor and the laser sensor ensures the absolute reliability of critical data in harsh environments. The cross-verification of the two data can identify the failure of a single sensor.

[0031] The data collected by the aforementioned sensors is transmitted to the data acquisition unit via sensor cables. After the data acquisition unit performs preliminary processing on the data collected by the sensors (e.g., signal amplification, noise suppression, dimension normalization, format encapsulation, and other existing mature technologies), the data can be uploaded to the edge computer via an industrial bus or IoT gateway.

[0032] The edge computer uses an industrial-grade embedded computer, deployed in the local control cabinet of the hydraulic gate hoist. It has a built-in AI diagnostic model (e.g., based on CNN-LSTM fusion algorithm), and achieves accurate diagnosis of multi-parameter correlation through data transmitted by the data acquisition device. This enables scientific early warning of hydraulic oil contamination, fatigue failure, aging failure, wear failure, corrosion failure, cavitation and cavitation, and various valve group failures, ultimately realizing predictive maintenance and intelligent management of the hydraulic gate hoist. The diagnostic analysis results of the edge computer are transmitted to the remote monitoring center / monitoring backend via wireless network.

[0033] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A multi-parameter integrated online monitoring system for hydraulic gate hoists, comprising a sensor monitoring module for data acquisition, a data acquisition unit for acquiring sensor data, and an edge computer communicating with the data acquisition unit, characterized in that: The sensor monitoring module includes a mechanical structure monitoring module, installed on the frame and key force transmission components of the hydraulic hoist, used to collect operational data of the mechanical structure; a power source monitoring module, installed on the oil tank and hydraulic pump outlet pipeline of the hydraulic system, used to collect hydraulic oil quality and pump operating status data; a valve group monitoring module, installed on the control valve group of the hydraulic hoist's hydraulic system, used to collect working status data of various valves, the control valve group including throttle valves, main valves, pilot valves, solenoid valves, directional valves, electromagnets, and proportional valves; and an actuator monitoring module, installed on the rod chamber, rodless chamber, and outer wall of the hydraulic cylinder, used to collect pressure, vibration, and displacement data of the hydraulic cylinder.

2. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 1, characterized in that: The power source monitoring module includes: an oil fluid integrated sensor, installed in the oil tank, for collecting data on the contamination level, moisture content, and oil temperature of the hydraulic oil; a vibration sensor, installed on the outlet pipeline of the hydraulic pump, for collecting vibration signals of the hydraulic pump; and a pressure sensor, installed at the outlet of the hydraulic pump, for collecting main pressure data of the hydraulic system.

3. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 2, characterized in that: The valve group monitoring module includes a valve body vibration sensor installed on the valve body of a proportional valve, directional valve, or relief valve; a pilot pressure sensor installed in the pilot control oil circuit where a pilot valve is installed; a set of downstream pressure sensors installed at the inlet and outlet ports of the directional valve or proportional valve; and an electromagnet current sensor integrated into the drive circuit of the solenoid valve or proportional valve to collect the drive current waveform data of the electromagnet.

4. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 3, characterized in that: The valve group monitoring module also includes a pressure compensator monitoring module, which is a differential pressure sensor. Its two pressure taps are respectively connected to the front and rear ends of the throttle valve port controlled by the pressure compensator, and are used to directly collect the working differential pressure data of the valve port.

5. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 4, characterized in that: The actuator monitoring module includes: a dual-chamber pressure sensor, which is respectively installed in the oil port of the rod chamber and the rodless chamber of the hydraulic cylinder; a cylinder vibration sensor, which is installed on the outer wall of the hydraulic cylinder; and a rope displacement sensor, which is used to measure the displacement of the hydraulic cylinder piston rod.

6. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 5, characterized in that: The actuator monitoring module also includes a non-contact displacement sensor, which is located near the piston rod of the hydraulic cylinder and is used to redundantly verify the measured values ​​of the displacement sensor in the actuator monitoring module.

7. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to claim 6, characterized in that: The mechanical structure monitoring module includes: a frame vibration sensor, installed on the load-bearing frame of the hydraulic hoist; and a stress sensor, installed on the connecting pin, bearing seat, and lifting head.

8. The multi-parameter integrated online monitoring system for hydraulic gate hoists according to any one of claims 1 to 7, characterized in that: The data acquisition device is a multi-channel synchronous acquisition device and communicates with the edge computer via industrial Ethernet or RS-485 bus.

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